Composite Aircraft Brake Piston Housing with Metal Frame

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Solution Overview

Problem

Aircraft brake assemblies face challenges in weight reduction using lightweight composite materials due to high temperatures and stresses, which can lead to deformation, misalignment, hydraulic fluid leakage, and improper operation.

Innovation Solution

A composite brake piston housing with embedded fibers and a frame made from a different material, formed by placing a frame in a mold with reinforcing fibers and a composite matrix material to create a lightweight yet rigid structure that can withstand high temperatures and pressures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If lightweight composite materials are used for brake piston housing, then weight is reduced, but structural strength and rigidity deteriorate under high temperature and pressure

Engineering Contradiction:

Improvehousing weightVSAvoidstructural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies composite materials by combining a metal frame (aluminum or aluminum alloy) with a composite body made of fibers (carbon, titanium, or nylon-66) embedded in a resin matrix (epoxy or phenolic). This composite structure achieves both weight reduction and maintained structural strength under high temperature and pressure conditions.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by using a metal frame specifically in regions requiring high strength and rigidity (such as mounting flanges and structural supports), while using lighter composite material in other areas. This localized application of different materials optimizes the balance between weight reduction and structural integrity.

Inventive Principle:

Principle #3Local quality

2Weight of moving object

If lightweight composite materials are used for brake piston housing, then weight is reduced, but resistance to deformation under high stress deteriorates

Engineering Contradiction:

Improvehousing weightVSAvoidresistance to deformation

Core Design Contradiction:

Weight of moving objectVSStability of the object's composition

Solution Approach 1:

The composite construction with metal frame and fiber-reinforced resin body provides both weight reduction and resistance to deformation under high stress conditions during brake operation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The housing is segmented into a metal frame structure and a composite body, allowing the frame to bear the primary structural loads and resist deformation, while the composite body provides lightweight coverage and thermal management.

Inventive Principle:

Principle #1Segmentation

3Weight of moving object

If lightweight composite materials are used for brake piston housing, then weight is reduced, but piston alignment precision deteriorates

Engineering Contradiction:

Improvehousing weightVSAvoidpiston alignment

Core Design Contradiction:

Weight of moving objectVSManufacturing precision

Solution Approach 1:

By segmenting the housing into a rigid metal frame and composite body, the frame provides stable, precise mounting features for pistons that maintain alignment under thermal and mechanical loads, while the composite body remains lightweight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal frame is strategically positioned at critical locations where piston alignment and mounting precision are required, ensuring that the lightweight composite material does not compromise alignment accuracy.

Inventive Principle:

Principle #3Local quality

4Weight of moving object

If lightweight composite materials are used for brake piston housing, then weight is reduced, but resistance to thermal stress and corrosion deteriorates

Engineering Contradiction:

Improvehousing weightVSAvoidresistance to thermal stress and corrosion

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The composite material system provides corrosion resistance while the metal frame handles thermal stress, achieving both weight reduction and reliability under extreme conditions.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The composite body acts as an intermediary between the external environment (thermal stress, corrosion) and the internal metal frame, protecting the frame while maintaining lightweight properties and thermal management capabilities.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS7614340B2Composite piston housing for aircraft brakes

Publication Date: 2009.11.10 HONEYWELL INTERNATIONAL INC

AI summary

An aircraft brake piston housing (10) has a composite body (14) including a plurality of fibers embedded in a matrix, the body (14) including a central bore (18) and a plurality of circumferentially disposed openings (23) surrounding the bore (18), at least some of the circumferentially disposed openings (23) being configured to receive a brake piston (26), and a frame (12) embedded in the composite body (14) and formed from a material different than the matrix. Also a method of forming such a brake piston housing.